Automated plumbing, wiring, and reinforcement

ABSTRACT

An apparatus may include a nozzle assembly configured to extrude material through an outlet; and a controllable robotic arm coupled to the nozzle assembly, the robotic arm having at one end a gripper configured to pick up an element and deposit the element at a desired position relative to the extruded material. The element may be one of: a reinforcement member for a structure being constructed; a segment of a plumbing pipe; an electric network component; and a tile.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 12/860,367, filed Aug. 20, 2010, entitled “Automated Plumbing,Wiring, and Reinforcement,” by inventor Behrokh Khoshnevis; which is acontinuation application of U.S. application Ser. No. 12/249,319, filedOct. 10, 2008, now abandoned, entitled “Automated Plumbing, Wiring, andReinforcement,” by inventor Behrokh Khoshnevis; which is a divisionalapplication of U.S. application Ser. No. 11/040,602, filed Jan. 21,2005, now U.S. Pat. No. 7,452,196, issued Nov. 18, 2008, entitled“Automated Plumbing, Wiring, and Reinforcement,”by inventor BehrokhKhoshnevis; which is based upon and claims priority to U.S. ProvisionalApplication No. 60/537,756, entitled “Automated Construction UsingExtrusion,” filed on Jan. 20, 2004, by inventor Behrokh Khoshnevis. U.S.application Ser. No. 11/040,602 is also a continuation-in-part of U.S.application Ser. No. 10/760,963, filed Jan. 20, 2004, now U.S. Pat. No.7,153,454, issued Dec. 26, 2006, entitled “Multi-Nozzle Assembly forExtrusion of Wall,”, also by inventor Behrokh Khoshnevis. The '963application is based upon and claims priority to U.S. ProvisionalApplication 60/441,572, entitled “Automated Construction,” filed on Jan.21, 2003, by inventor Behrokh Khoshnevis. The entire contents of all ofthese applications are incorporated herein by reference.

U.S. application Ser. No. 11/040,602 is also related tocontemporaneously-filed U.S. application Ser. No. 11/040,401, filed Jan.21, 2005, now U.S. Pat. No. 7,641,461, issued Jan. 5, 2010, entitled“Robotic Systems for Automated Construction,” by inventor BehrokhKhoshnevis; and U.S. application Ser. No. 11/040,518, filed Jan. 21,2005, entitled “Mixer-Extruder Assembly,” by inventor BehrokhKhoshnevis. The entire contents of all of these applications areincorporated by reference.

GOVERNMENT'S INTEREST IN APPLICATION

This invention was made with government support under Grant Nos. 9634962and 9522982 awarded by the National Science Foundation. The governmenthas certain rights in the invention.

BACKGROUND

Constructing homes, offices, boats and other structures has an ancientheritage. Despite all of the centuries of development, however, therecan be difficulties and problems.

Construction is usually very labor intensive. Even a modest sizestructure usually requires the efforts of numerous individuals. This canbe very costly. Simultaneously using the time of numerous individuals inan efficient manner can also be challenging.

The results of the construction effort can also be inconsistent. Theappearance and quality of one structure can vary from another built fromthe same design. This can be caused by differences in the skills,efforts, supervision and techniques employed by those that work on thestructures.

Construction may also result in wasted material. For example, when woodis used, standard, off-the-shelf lengths must often be cut to meetdesign requirements, resulting in waste.

Construction using manual labor can also be very time-consuming,requiring months and, in some instances, years to complete.

Construction can also be hazardous. Many construction workers are killedor seriously injured at construction sites, including about 500,000 inthe United States alone.

SUMMARY

A multi-nozzle assembly may include a first nozzle configured to extrudematerial through a first outlet; a second nozzle configured to extrudematerial through a second outlet; and a third nozzle configured toextrude material through a third outlet, the third outlet being betweenthe first and second outlets.

A construction method may include simultaneously extruding a first layerof two, spaced apart rims. After extruding the first layer of rims, afurther layer of two, spaced apart rims may simultaneously be extruded,each directly or indirectly on top of one of the spaced apart rims inthe first layer, along with a first layer of filler between the firstlayer of two, spaced apart rims.

A wall may include a set of spaced apart rims, each comprised of astacked set of separately-extruded layers; and a filler between the rimscomprised of a stacked set of separately-extruded layers.

A robotic system may include a movable gantry robot, and a nozzleassembly movably coupled to the gantry robot. The gantry robot mayinclude an overhead beam extending between, and supported by, at leasttwo side members slidably mounted on a pair of rails. The nozzleassembly may be coupled to the overhead beam of the gantry robot, andmay be configured to extrude material through an outlet. The roboticsystem may further include a position controller configured to controlposition and movement of the gantry robot and the nozzle assembly.

A construction apparatus may include a movable gantry platform having across-member extending between, and slidably mounted across, a pair ofopposite side-members. A nozzle assembly may be movably coupled to thecross-member and configured to extrude material through an outlet. Alifting mechanism may be configured to controllably lift the gantryplatform to a height sufficient for the nozzle assembly to extrude alayer of material on top of a previously extruded layer of material.

A mobile robotic system may include a movable robotic base; anarticulated robotic arm extending from the robotic base; a nozzleassembly coupled to a distal end of the robotic arm and configured toextrude material through an outlet; and a material feeding systemmounted on the robotic base and configured to feed material to thenozzle assembly.

A mobile robotic system may include a motorized wheel assembly; a nozzleassembly coupled to the motorized wheel assembly and configured toextrude material through an outlet; and a material feed system mountedon the motorized wheel assembly and configured to feed material to thenozzle assembly.

An apparatus may include a nozzle assembly configured to extrudematerial through an outlet; and a controllable robotic arm coupled tothe nozzle assembly, the robotic arm having at one end a gripperconfigured to pick up an element and deposit the element at a desiredposition relative to the extruded material.

An apparatus may include a nozzle assembly configured to extrudematerial through an outlet; a controllable robotic arm coupled to thenozzle assembly; and a painting mechanism attached to one end thereof,the painting mechanism configured to controllably paint a surface ofextruded material, in accordance with a desired specification.

A three-dimensional structure may include a set of spaced apart rims,each comprised of a stacked set of separately extruded layers; a fillerbetween the rims comprised of a stacked set of separately-extrudedlayers; a plurality of conduits defined at least in part by the spacedapart rims and the filler; and one or more elements installed within atleast some of the conduits. The elements may include reinforcementmembers; segments of a plumbing pipe; and electric network components.

A method of installing tiles may include manipulating a robot to inducethe robot to apply a layer of adhesive material on a surface of materialextruded and shaped by a nozzle assembly; and operating the robot tocause the robot to pick up one or more tiles and to deposit the tiles atdesired locations over the layer of adhesive material.

A mixer-extruder assembly may include a hollow cylindrical chamber and ahopper connected to the chamber. The chamber may include an outlet portat a lower end thereof, and a fluid inlet port. The hopper may have aninput port configured to receive input material therethrough. A pistondrive shaft having a piston attached at one end may be rotatable about adrive shaft axis that is coaxial with the cylindrical chamber. Thepiston may have one or more mixer blades coupled thereto and rotatabletherewith. The piston be controllably rotated about the drive shaftaxis, after input material received through the input port of the hopperis delivered into the chamber, causing the mixer blades to rotate andmix the input material with mixing fluid introduced through the fluidinlet port of the chamber. The piston may also be slidably movable froman upper end of the chamber toward the outlet port of the chamber, sothat the mixed input material is extruded through the output port of thechamber.

A method of mixing and extruding material may include providingpowderized material to a hopper connected to a substantially cylindricalchamber; transferring at least some of the powderized material from thehopper to the extrusion chamber; introducing mixing fluid into theextrusion chamber; and rotating a piston within the chamber about adrive axis that is coaxial with the cylindrical chamber. The piston mayhave one or more mixing blades coupled thereto and rotatable therewith,so that the rotation of the piston causes the mixing blades to mix thepowderized material with the mixing fluid. The method may furtherinclude moving the piston from an upper end of the chamber toward anoutlet port of the chamber, so that the powderized material mixed withthe mixing fluid is extruded from the chamber through the outlet port.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates one embodiment of a nozzle assembly that includes asingle nozzle.

FIG. 2 illustrates the embodiment of the nozzle assembly shown in FIG. 1being used to extrude a wall.

FIG. 3 illustrates another embodiment of a nozzle assembly that includesthree nozzles.

FIGS. 4( a)-(c) illustrate the embodiment of the nozzle assembly shownin FIG. 3 being used to extrude a wall.

FIG. 5 illustrates the embodiment of the nozzle assembly shown in FIG. 3being used to extrude a wall in an angled orientation.

FIG. 6 illustrates a nozzle assembly having an orientation controlmechanism being used to construct an embodiment of a supportless roof.

FIG. 7 illustrates the supportless roof shown in FIG. 6 in its completedstate atop a wall structure.

FIG. 8 illustrates another embodiment of a nozzle assembly that includesa slot in a central nozzle that accommodates reinforcement members.

FIG. 9 illustrates the nozzle assembly shown in FIG. 8 being used toconstruct a wall having reinforcement members.

FIG. 10 illustrates another embodiment of a nozzle assembly.

FIG. 11 illustrates certain components of the nozzle assembly shown inFIG. 10 in an unassembled form having a central nozzle at a height lowerthan interior and exterior nozzles.

FIG. 12 illustrates a bottom view of a portion of the nozzle assemblyshown in FIG. 10.

FIG. 13 illustrates an embodiment of a nozzle including a controllablefront and rear gate.

FIG. 14 illustrates one embodiment of a nozzle assembly using the typeof nozzle shown in FIG. 13 being used to extrude a wall.

FIG. 15 illustrates the nozzle shown in FIG. 13 being used to extrude aninsulation layer.

FIG. 16 illustrates a nozzle assembly using the nozzle shown in FIG. 13being used to extrude a wall with a layer of insulation.

FIG. 17 illustrates another embodiment of a nozzle assembly having slotsin a gate being used to extrude a wall with interlocked layers.

FIGS. 18A and 18B illustrate another embodiment of a nozzle assemblyhaving variable width nozzles.

FIG. 19 illustrates one embodiment of a robotic system that includes amovable gantry robot to control the position of the nozzle assembly.

FIG. 20 illustrates a movable gantry platform, an adaptive platform, anda laser rangefinder included in the movable gantry robot shown in FIG.19.

FIGS. 21A and 21B illustrate a perspective view and a top view,respectively, of one embodiment of a construction apparatus having alifting mechanism to build high-rise structures.

FIG. 22 illustrates one embodiment of anchoring elements that anchor thegantry platform shown in FIGS. 20 and 21A-21B to a rigid structure.

FIGS. 23A and 23B illustrate another embodiment of a lifting mechanismfor the construction apparatus illustrated in FIGS. 21A and 21B.

FIG. 24 illustrates another embodiment of a movable gantry robotincluding a plurality of cross-members that each holds a nozzleassembly.

FIG. 25 illustrates one embodiment of a mobile robotic system.

FIG. 26 illustrates the mobile robotic system shown in FIG. 25 beingused to construct a wall.

FIG. 27 illustrates a plurality of the mobile robotic systems, shown inFIG. 25, operated concurrently for construction.

FIG. 28 illustrates another embodiment of a mobile robotic system thatis equipped with a motorized wheel assembly.

FIG. 29 illustrates the mobile robotic system shown in FIG. 28 beingused to create corners.

FIG. 30 illustrates the mobile robotic system shown in FIG. 29 climbingfrom a completed layer to the next layer.

FIG. 31 illustrates insertion of reinforcement staples by a robotic armcoupled to a nozzle assembly.

FIG. 32 illustrates vertical rods inserted within a wall forreinforcement.

FIGS. 33A, 33B, and 33C illustrate the insertion of reinforcementelements for walls.

FIGS. 34A, 34B, 34C, 34D illustrate the insertion of reinforcementelements for columns.

FIG. 35 illustrates the installation of vertical plumbing pipe segments,under automated robotic control.

FIG. 36 illustrates a robotic arm including a plurality of grippersconfigured to grasp desired elements from different orientations.

FIG. 37 illustrates a robotic gripper having a movable heater elementconfigured to grasp plumbing pipe segments with downward opening.

FIG. 38 illustrates installation of horizontal plumbing pipes.

FIG. 39 illustrates alignment of pipe segments, when assembling aplumbing pipe network from the pipe segments.

FIG. 40 illustrates the shielding of plumbing networks.

FIG. 41 illustrates electric modules for building electrical andcommunication networks.

FIG. 42 illustrates a robotic gripper that grasps and inter-connect theelectric modules shown in FIG. 41.

FIG. 43 illustrates the positioning of the electric modules withincorresponding openings in the walls.

FIG. 44 illustrates automated tiling of floors.

FIG. 45 illustrates automated tiling of walls.

FIG. 46 illustrates automated painting of surfaces of constructedstructures.

FIG. 47 illustrates automated roof construction.

FIGS. 48A and 48B show a mixer-extruder assembly.

FIG. 49 illustrates a cross-sectional view of the mixer-extruderassembly shown in FIG. 48, as well as a piston drive mechanism insidethe extrusion cylinder.

FIG. 50 illustrates the operation of the mixer-extruder assembly shownin FIGS. 48 and 49, as the piston is moved from an upper end of theextrusion chamber toward the outlet port of the chamber.

DETAILED DESCRIPTION

FIG. 1 illustrates an embodiment of a nozzle assembly that includes asingle nozzle. As shown in FIG. 1, a nozzle assembly 101 may include anozzle 103 having an outlet 105 (not visible in FIG. 1), a trowel 107,and a trowel positioning controller, including a servo motor 109 andtrowel linkage 111 and 113.

Although shown as cylindrical, the shape of the nozzle 103 may vary. Itmay include an inlet 115 for material in a fluid or semi-fluid form.

The cross-section of the outlet 105 may vary. It may be circular,rectangular or of some other shape.

FIG. 2 illustrates the embodiment of the nozzle assembly shown in FIG. 1being used to extrude a wall. As shown in FIG. 2, the nozzle assembly101 is extruding a layer of material 203 while being moved in ahorizontal direction 208. The trowel 107 smoothens the exterior surfaceof the layer of material 203 as it is being extruded from the nozzle103. The lower surface 205 of the member that supports the nozzle 103has an opening (not shown) through which the extruded material flows.The lower surface 205 may also act as a trowel to smoothen the uppersurface of the layer of material 203 that is being extruded. Anadditional trowel (not shown) may also be included to smoothen theinterior surface of the layer 203 that is being extruded. Alternatively,a sharp blade parallel to the first trowel may cut out excess materialon the interior side to create a planar surface.

Referring again to FIG. 1, the height of the trowel 107 may becontrolled by the trowel position controller which, as explained above,includes the servo motor 109 and the trowel linkages 111 and 113. Theheight of the trowel 107 may be adjusted to correspond to the height ofthe extruded layer 203. By making the height of the trowel 107adjustable, layers of different thickness may be extruded.

Although the smoothening surface of the trowel 107 and the underneathsurface 205 are illustrated as being flat, other contours may be usedinstead.

Any type of material may be used and delivered into the inlet 115,including cement or plastic. The material may be delivered in a liquidor quasi-liquid form and may include or receive additives or may havecharacteristics that cause the material to harden into a solid afterextrusion.

As is apparent from an examination of FIG. 2, the nozzle assembly 101may be moved horizontally in a back-and-forth motion, each time beingelevated in height by approximately the thickness of each extrudedlayer. The collective effect is to create a wall 207 consisting of astacked set of separately-extruded layers.

The horizontal direction 208 of the nozzle assembly 101 at the end 209of a pass may be altered by 90 degrees into the direction 111. This canproduce an extruded wall that has a sharp right angle bend. Obviously,other types of changes in direction may be used to create other wallshapes, including curved walls and walls that join one another at anglesother than 90 degrees.

FIG. 3 illustrates another embodiment of a nozzle assembly that includesthree nozzles. As shown in FIG. 3, a nozzle assembly 301 includes anexterior nozzle 303, an interior nozzle 305 and a central nozzle 307.The exterior nozzle 303 may include an outlet 309, the interior nozzle305 may include an outlet 311, and the central nozzle 307 may include anoutlet 313. Although each outlet is illustrated as having a rectangularcross-section, other cross-sectional shapes could be used instead, suchas round or oval. The width of the central outlet 313 may be equal to,greater or less than the width of the exterior outlet 309 or theinterior outlet 311. The width of the exterior outlet 309 may be equalto or different than the width of the interior outlet 311

A trowel 315 may be used to smooth the material that is extruded fromthe exterior outlet 309, while a trowel 317 may be used to smooth thematerial that is extruded from the interior outlet 311. The height ofthe exterior trowel 315 and the interior trowel 311 may, in turn, becontrolled by trowel position controllers 319 and 318, respectively.

FIGS. 4( a)-(c) illustrate the embodiment of the nozzle assembly shownin FIG. 3 being used to extrude a wall.

As shown in FIG. 4( a), a first layer of a wall 403 may be extruded bymoving the nozzle assembly 301 in a horizontal direction and byextruding material only through the exterior nozzle 303 and the interiornozzle 305. During this pass, no material may be extruded from thecentral nozzle 307.

This approach may cause an exterior rim layer 405 and an interior rimlayer 407 of material to be extruded. Since no material is beingextruded during this pass from the central nozzle 307, no significantforce will be placed on the interior walls of the rim layers 405 and407.

The rim layers may then be left to cure and thus harden. Variousapproaches such as thermal and chemical may be used to speed up thecuring process. For example, a torch, hot air blower, or microwaveenergy may be attached to the nozzle assembly 301 (not shown) to treatthe extruded material and speed its curing. A judicious choice ofmaterial may also be made for the rims, that cures quickly, such asplastic.

As shown in FIG. 4( b) another rim layer may be extruded on top of therim layer that has hardened. This may consist of a second exterior rim413 being extruded on top of the first exterior rim 405 and a secondinterior rim 415 being extruded on top of the first interior rim 407. Afirst filler layer 411 may also be extruded between the first rim layers405 and 407 by extruding material from the central nozzle 307 at thesame time that the second rim layers 413 and 415 are being extruded. Thefiller may be of a much stronger material, such as cement. The fillermaterial may or may not dry as quickly as rim material.

If the rim layers are able to cure quickly enough, and if their lengthis long enough, the nozzle assembly 301 may be able to return to thebeginning of a pass to extrude the next layer of rims on top of theprevious layer as soon as extrusion of the previous layer is complete.If the curing is fast enough, the nozzle assembly may instead bedirected to extrude its next layers of material during the returntraverse. Other sequences could also be followed, including a restbetween traverses.

The process may be repeated until the height of the wall 403 reaches theneeded level. FIG. 4( c) illustrates the wall 403 with six layers. Afterthe last needed rim layers are extruded, the next pass may extrude onlya filler layer, thus completing the wall structure.

Delaying the extrusion of filler layers helps insure that the rim layerswill be strong enough to contain their neighboring filler layers. Ofcourse, the extrusion of each filler layer need not always or even everbe exactly one traverse behind the extrusion of each neighboring rimlayer. In other embodiments, the filler layers might be two or morelayers behind the neighboring rim layers. Indeed, none of the fillerlayers might be extruded until after all or at least several of the rimlayers have been extruded and hardened. In this embodiment, the entirewall filler or at least a large portion of it could be extruded in asingle pass.

FIG. 5 illustrates the embodiment of the nozzle assembly shown in FIG. 3being used to extrude a wall at an angled orientation.

Material to be extruded may be delivered through outer tubes 517, 519,521 and 523. Each of these outer tubes may contain within them a set ofinner tubes, one channeling material to the exterior outlet 309 (seeFIG. 3) and the interior outlet 311 (see FIG. 3), while the otherchanneling material to the central outlet 313 (see FIG. 3). In this way,the type of material that is delivered to the exterior outlet 309 andthe interior outlet 311 may be different from the material that isdelivered to the central outlet 313.

In another embodiment, each outer tube 517, 519, 521 and 523 may includethree interior tubes, allowing a different type of material to bedelivered to the exterior outlet 309 and the interior outlet 311 aswell.

As also shown in FIG. 5 (and partially in FIG. 3), the nozzle assembly101 may include an orientation control mechanism that can cause theoutlets 309, 311 and 313 to be pointed in almost any direction. Any typeof control mechanism may be used, including a control mechanism that iscapable of orienting the outlets in one, two or three degrees offreedom. With respect to the nozzle assembly 101 shown in the figures,an orientation control mechanism has been selected that allows theoutlets to be oriented in three dimensions. The orientation controlmechanism may include servo motors 501, 503 and 505, each controlling aseparate axis of orientation. Of course, appropriate internal structuresmay be included to translate the motion of these servo motors into thenecessary movement. In certain embodiments, positioning information maybe sent back to a servo controller (not shown) and used in one or morefeedback loops to maximize the accuracy of the positioning that isobtained. Appropriate material channeling chambers and gaskets may alsobe included (not shown) to ensure that the material continues to flowwithout significant leakage in the moving joints, regardless of theangular orientation that is directed. The nozzle assembly may itself bemoved around by a XYZ positioning system, thus providing 6 degrees offreedom to the nozzle head.

Although nozzle assemblies having only a single or three nozzles havethus-far been illustrated, it is to be understood that a differentnumber of nozzles could be used, depending upon the application, such astwo, four or even more.

FIG. 6 illustrates a nozzle assembly having an orientation controlmechanism being used to construct an embodiment of a supportless roof.FIG. 7 illustrates the supportless roof shown in FIG. 6 in its completedstate atop a wall structure. Collectively, these figures demonstrate howthe positional flexibility of the nozzle assembly can facilitate theconstruction of supportless roofs, such as vaults. Although a nozzleassembly having only a single nozzle is illustrated, it is to beunderstood that a different number of nozzles could be used, such as thetriple nozzle assembly shown in FIGS. 3-5.

FIG. 8 illustrates another embodiment of a nozzle assembly that includesa slot in a central nozzle that accommodates reinforcement members. FIG.9 illustrates the nozzle assembly shown in FIG. 8 being used toconstruct a wall having reinforcement members.

As shown in FIG. 8, a nozzle assembly 801 includes an exterior nozzle803 having an outlet 805, an interior nozzle 807 having an outlet 809and a central nozzle set consisting of two nozzles 811 and 813 havingoutlets 815 and 817, respectively, that are separated by an opening 819.FIG. 9 illustrates how the opening 819 ensures that the nozzle assembly801 does not collide with reinforcing members 821, 823 or 825 duringoperation.

FIG. 10 illustrates another embodiment of a nozzle assembly. As shown inFIG. 10, a nozzle assembly 1001 may include an exterior nozzle 1003 andan associated trowel 1005, an interior nozzle 1007 and an associatedtrowel 1009, and a central nozzle 1011. An inlet 1013 may be provided toreceive material that is channeled to the central nozzle 1011 forextrusion, while an inlet 1015 may be provided to receive material thatis channeled to the exterior nozzle 1003 and to the interior nozzle 1007for extrusion. A bevel gear 1017 may be provided to rotate the nozzles.

Servo motors 1019 and 1021 may be used to control the height of thetrowels 1009 and 1005, respectively. A servo motor 1025 may be used tocontrol an internal gate valve (not shown) that is used to regulate theflow of material to the exterior nozzle 1003. Similarly, a servo motor1023 may be used to control an internal gate valve (not shown) that isused to regulate the flow of material to the interior nozzle 1007. Theflow of material to the central nozzle 1011 may also be regulated in asimilar or different manner.

When making a curved wall, the rim material delivery rate may bedifferent for the exterior and interior outlets. This may be effectuatedby appropriate settings of the servo motors 1023 and 1025. The valve maybe near or away from the nozzle. The gate valves may be configured tocontrollably adjust the volume of flow, as well as to completely cut theflow off.

A servo motor 1027 may be used to control the height of the centralnozzle 1011 with respect to the external nozzle 1003 and the internalnozzle 1007. The heights of the external and/or internal nozzles mayalso be controlled in a similar or different manner.

FIG. 11 illustrates certain components of the nozzle assembly shown inFIG. 10 in an unassembled form with the central nozzle 1011 at a heightlower than the interior nozzle 1007 and the exterior nozzle 1003. Such aheight differential may be useful in embodiments in which each centralfiller layer is extruded one pass behind each surrounding rim layer. Theability to control the relative heights of the nozzles may also beuseful in applications in which there is a need to avoid occasionalobstructions.

FIG. 12 illustrates a bottom view of a portion of the nozzle assembly1001 shown in FIG. 10. It provides more detail on how the servo motor1029 may control the height of the central nozzle 1011 with respect tothe exterior nozzle 1003 and the interior nozzle 1007. This detailincludes a drive belt 1031 that causes ball screws 1132 and 1134 (seeFIG. 11) to rotate and to thus cause a corresponding change in theelevation of the central nozzle 1011 due to interaction with associatedthreaded sleeves 1137 and 1139 (FIG. 11), respectively.

FIG. 13 illustrates an embodiment of a nozzle including a controllablefront and rear gate. As shown in FIG. 13, a nozzle 1301 includes acontrollable front gate 1303 and a controllable rear gate 1305. Thecontrollable gate 1303 may be controlled by a gate controller, such as aservo motor 1307 and an associated coupling 1309. Similarly, thecontrollable gate 1305 may be controlled by a gate control mechanism,such as a servo motor 1311 and an associated control mechanism 1315.

FIG. 14 illustrates one embodiment of a nozzle assembly with the nozzleshown in FIG. 13 being used to extrude a wall. This embodiment allowsthe beginning and end of each extruded layer to be shaped with a sharpvertical surface by appropriate control of the gates.

FIG. 15 illustrates the nozzle shown in FIG. 13 being used to extrude aninsulation layer. In this embodiment, a polystyrene filament may be fedthrough an electrically heated barrel 1501 so that molten plastic comesout through a nozzle 1503. Compressed air may be mixed in as well tocause a bead of Styrofoam 1505 to be created. One or more of theselayers may serve as insulation. Other types of polymers or othermaterials may be used instead.

FIG. 16 illustrates a nozzle assembly using the nozzle shown in FIG. 13to extrude a wall with insulation. As shown in FIG. 16, a wall 1601 isbeing extruded by a nozzle assembly 1603 (shown only in part) thatincludes a stacked set of Styrofoam layers 1605, 1607 and 1609.

FIG. 17 illustrates another embodiment of a nozzle assembly having slotsin a gate being used to extrude a wall with interlocked layers. As shownin FIG. 17, a gate 1701 includes slots 1703 and 1705 that causecorresponding ribs 1707 and 1709 to be created during the extrusion ofthe layer 1711. These create interlocking ribs, such as the interlockingribs 1713, 1715 and 1717, thus strengthening the wall that is extruded.

FIGS. 18 (a) and (b) illustrate another embodiment of a nozzle assemblyhaving variable width nozzles. As shown in FIGS. 18( a) and (b), anozzle assembly 1801 includes an exterior nozzle 1803, a central nozzle1805 and an interior nozzle 1807. The width of the layer that isextruded from the exterior and interior nozzles 1803 and 1807,respectively, may be varied by adjusting the relative separation ofthese nozzles, either manually or automatically under servo control.FIG. 8( a) illustrates the exterior and interior nozzles being widelyseparated for a wider rim layer, while FIG. 8( b) illustrates these samenozzles being compressed together for a narrower rim layer. The flowrate of the extruded material may be reduced during a wider setting toinsure that a full layer is extruded. The separating distance betweenthe two rim nozzles may be varied during the extrusion of a structure tofacilitate the construction of structures such as domes with aprogressively thinning wall or to make certain walls, such as interiorwalls, thinner than other walls, such as exterior walls. Appropriateadjustments could also be made to make one rim layer thinner than theother.

Sensors (not shown) may be inserted within a structure beingconstructed, to provide feedback regarding construction performance.After the structure is completed, these sensors may continue to be usedto report on information about the structure, such as heat, humidity,and deformation.

In one embodiment of a nozzle assembly, the nozzle assembly may includea roller that follows the extrusion and creates textures on the walls ofthe layers that are extruded.

A broad variety of construction applications may advantageously utilizeone or more of the nozzle assemblies that have now been described.

For example, a nozzle assembly may be attached to an arm of a roboticsystem. Under computer or other control, the nozzle assembly may extrudethe walls of an entire building, including several rooms. A gantrysystem may be used to support and position the nozzle assembly as ittraverses the needed paths. A positioning system may also be used toaccurately position the nozzle assembly, such as a system that includesfixed reference points and a laser rangefinder mounted on the nozzleassembly.

FIG. 19 illustrates one embodiment of such a robotic system thatincludes a movable gantry robot to control the position of the nozzleassembly. As shown in FIG. 19, a robotic system 1900 may include amovable gantry robot 1910 slidably mounted on a pair of rails 1940, andhaving a movable gantry platform 1950 to which a nozzle assembly 1960 isattached. The movable gantry robot 1910 may have an overhead beam 1920that is supported by, and extends between, at least two side members1930 that are slidably mounted on the pair of rails 1940. The movablegantry platform 1950 may be slidably mounted to the overhead beam 1920,and the nozzle assembly 1960 (shown only partially in FIG. 19) may beattached to the gantry platform 1950 in such a way that the nozzlesassembly follows the motion of the gantry platform 1950.

The robotic system 1900 may include a position controller that controlsthe position and movement of the gantry robot 1910 along the rails, aswell as the position and movement of the gantry platform 1950 and thenozzle assembly 1960. The position controller may include a positionsensor 1970 that senses the position of the nozzle assembly, and anactuator 1972 that controllably moves the nozzle assembly to a desiredposition, in response to the output of the position sensor 1970. Theposition sensor 1970 may be a laser rangefinder 1970, for example,illustrated schematically in FIG. 19, although any other positiondetection device known in the art may be used. Three reflectors 1974installed on fixed poles installed at the construction site may providefixed reference points for the laser rangefinder 1970.

The laser rangefinder 1970 (also called a lidar or a laser tracker) maybe a laser device that can accurately measure the distance to an objectby sending out light to the object and analyzing the light that isreflected/scattered off of the object. The range to the object may bedetermined by measuring the time for the light to reach the object andreturn. The laser rangefinder 1970 may include: 1) a transmitter (notshown) that generates laser light and transmits the laser light towardthe reflectors 1974; 2) a receiver (not shown) configured to receive thetransmitted light that is back-scattered from retroreflectors 1974 atthe reference points; 3) a photodetector (not shown) configured todetect the intensity of the light received by the receiver; and 4) adata acquisition system (not shown), effective to compute the distanceto the object by making time-of-flight measurements, i.e. by measuringthe time required for the light to reach the object and return.

A material feed system 1980 that is configured to feed material to thenozzle assembly 1960 may be coupled to the gantry robot 1910. Thematerial feed system 1980 may include a container 1982 configured tostore material, and an articulated feeding tube 1984 configured to feedmaterial stored in the container 1982 to the nozzle. The material maypumped in a premixed form by the ground based articulated delivery arm1984, by analogy to conventional concrete pump systems. In the lattercase, the articulated delivery arm 1984 may be passive, in which case itmay be rigidly attached to the gantry platform, i.e. the connectingmember 1990 between the delivery arm 1984 and the gantry platform may berigid. In this configuration, the gantry robot delivers the necessaryforce to move the feeding tube. An excessive opposing force may beexerted in this case, however, due to the inertia of the possibly highmass of the material feed system.

In an alternative arrangement, the material feed system may have its ownactive drive mechanism controllable by a joystick (not shown). In thisembodiment of the robotic system, the gantry robot may activate thejoystick, and the material feed system may follow the gantry robot. Inthis master/slave control setting, the material delivery arm should notbe rigidly connected to the gantry robot, because the delays andimprecision involved in positioning would necessitate a flexibleconnection 1990 between the gantry robot and the material delivery arm,to compensate for the positioning lags and errors.

Due to large size and potentially high weight of the members of therobotic system 1900, as well as the acceleration/deceleration inmotions, a considerable flexing may occur in the gantry robot. It maythus be difficult to maintain an accurate position for the nozzleassembly. To correct for such flexing and other positioning errors ofthe nozzle assembly, a second adaptive platform 1976 with a highlyresponsive servo system may be attached to the gantry platform 1950.

FIG. 20 illustrates in more detail such an adaptive platform 1976equipped with a laser rangefinder 1970 and attached to the movablegantry platform, in the gantry robot shown in FIG. 19. The adaptiveplatform 1976 may be equipped with a laser rangefinder 1970, or otherposition sensing devices such as devices using atomic clocks andelectromagnetic waves. The laser rangefinder 1970 accurately senses theplatform position using the three fixed reference points 1974 installedat the construction site. The nozzle assembly 1960 may be installed onthe adaptive platform 1975. The nozzle assembly 1960 may include anozzle 1962 configured to extrude material from an outlet 1964, and atrowel 1966 configured to shape material extruded from the nozzle 1962.As the gantry platform makes inaccurate moves, for example due tostructural flexing, the adaptive platform (equipped with a laserrangefinder or other type of position detection device), accuratelymaintains the desired course using the three fixed reference pointsinstalled at the construction site. The possible range of the adaptiveplatform motion in any direction may be at least as large as the maximumaggregate flexing and positioning error of the gantry platform.

To build high-rise structures, a robotic system may use a liftingmechanism that controllably lifts the gantry platform to a desiredheight. FIGS. 21A and 21B illustrate a perspective view and a top view,respectively, of one embodiment of a construction apparatus 2100 havinga lifting mechanism to build high-rise structures. In the embodimentillustrated in FIGS. 21A and 21B, several cranes 2160 that lift thegantry platform by means of cables 2170 may be used. The constructionapparatus 2100 may include a movable gantry platform 2120 having across-member 2110 that is slidably mounted across a pair of oppositeside-members 2120 and extends therebetween. The gantry platform may besupported by the cables 2170 extending from the cranes 2160.

The lifting mechanism may be configured to controllably lift the gantryplatform to a height sufficient for the nozzle assembly 2130 to extrudea layer of material on top of a previously extruded layer of material.The cable lift mechanism, which may be performed successively after aspecified number of layers are constructed, may perform coarsepositioning in the vertical direction, by causing the cables tocollectively hoist the gantry platform to a desired height. The nozzleassembly may have its own Z motion control for a limited range. Theillustrated cable lift mechanism may lift the nozzle assembly layer bylayer, and in constructing each layer the nozzle assembly may adaptivelycompensates for cable positioning inaccuracy.

The main gantry platform 2108 may have an extension platform 2140 thatholds the material (concrete batch, beams, plumbing modules, etc.) andcan be accessed by a robotic manipulator 2150 that rides on the samemain platform 2108 and that is connected to the nozzle assembly 2130.Material on the main platform 2108 may be periodically replenished bymeans of elevators (not shown) or conventional construction cranes.

FIG. 22 illustrates the anchoring of the gantry platform 2108 shown inFIGS. 20 and 21A-21B to a rigid structure. As cables cannot deliverlateral stiffness, the body of the building structure, which isgenerally very rigid, may be used to anchor the gantry platform. Thismay be done by means of attachments that have accurate wheels that aretightly in touch with the well cured (several layers below the freshlydeposited layers) building external wall surfaces. One or moreattachment members 2210 may extend from points along the gantryplatform. Each attachment member 2210 may have a wheel 2220 affixedthereto. The wheels 2220 may deliver lateral stiffness to the gantryplatform when the wheels 2220 are tightly in touch with the externalsurfaces of the well cured building wall, several layers below thefreshly deposited layers. An adaptive positioning system may be builtinto some of the attachment members 2210, in order to compensate forsmall possible dimensional errors, so that all wheels 2210 around theplatform 2108 are kept in touch with the building structure.

In the beginning of the construction process, when there is no buildingstructure to anchor against, the gantry platform 2108 may rigidly reston the ground. The initial, lower section of the building may beconstructed by means of elevating the nozzle by its own vertical motioncontrol mechanism. When the highest limit of the motion controlmechanism has been reached, the cable lifting system may be activated.By this time the constructed building section may provide stiff supportto the suspended gantry frame, be means of wheeled attachments 2210 and2220, described above.

FIG. 23A illustrates another embodiment of a lifting mechanism for theconstruction apparatus illustrated in FIGS. 21A and 21B. As seen in FIG.23A, in this embodiment of a lifting mechanism, cable cranes are notused to lift the gantry platform, but rather the gantry platform mayclimb the building by means of vertically reciprocating legs 2310. Eachleg 2310 may have a pin drive mechanism that can extend and retractconical headed pins 2320 into and out of metal tubing sections 2330. Themetal tubing sections may be robotically embedded into the walls, uponlayer wise construction. The pins 2320 may be spaced by a desired numberof layers.

FIG. 23B illustrates the construction of several stories of a high-risestructure, using the lifting mechanism illustrated in FIG. 23A. As seenin FIG. 23A, this type of lifting mechanism requires minimal set up andis practically unlimited as to the height of the structure that it canbuild.

The support metal tubing sections, which may be visually unappealing onthe constructed building, may be cosmetically covered by plastic plugs,or permanently plastered or cemented closed. Leaving the metal tubingsections 2330 reusable may facilitate other automated systems such aspainting systems, window washing systems, and robotics emergency rescuesystems. The frame lifting approach disclosed here thus has generalapplications and is not limited to construction of structures usingextrusion by a nozzle assembly.

In one embodiment of a robotic system, a plurality of nozzle assembliesmay simultaneously be employed, instead of one large gantry system and asingle nozzle assembly traversing the layers of the entire structure.FIG. 24 illustrates another embodiment of a construction apparatus 2400having an overhead gantry platform 2408 that includes a plurality ofcross-members 2410. To build large structures such as apartmentbuildings, hospitals, schools and government buildings, the overheadgantry platform 2408 may extend above the width of the large structures.Two sets of cranes 2460, each riding on rail tracks 2430 laid alongsidethe structure, may be used to lift the platform. The platform 2408 maybe equipped with multiple cross members 2410, each holding a nozzleassembly 2130 and a robotic manipulator 2150 coupled to the nozzleassembly. Each cross member 2410 may be slidably mounted across a pairof opposite side-members 2420 (for beam installation, plumbing, etc.).

The side cranes 2460 may move infrequently, and stop at a selectedpositions while construction takes place at those positions. While theside cranes are stopped at a given position, and the gantry platform isheld at the given position, all necessary construction under theplatform may be performed, for several layers. The platform may then bemoved by the side cranes 2460 to the next position, and the constructionmay be resumed. This cycle may be repeated until completion of thelarge-scale structure. For very large structures, multiple crane/gantryplatform assemblies may be used concurrently.

In another embodiment of a robotic system, mobile robotics may be used.FIG. 25 illustrates one embodiment of a mobile robotic system 2500,having a movable robotic base 2510, and an articulated robotic arm 2520extending from the robotic base 2510. The mobile robotic system 2500 mayuse a conventional joint structure, and be equipped with materialstorage containers and delivery pipes. A nozzle assembly 2530 may becoupled to the distal end or the end effector of the robotic arm 2520,and can be lifted by the robotic arm 2520 to a desired height above therobotic base 2510. The nozzle assembly 2530 can thus reach from theground level all the way to the top of a wall. A material feeding system2550 may be mounted on the robotic base 2510, and may be configured tofeed material to the nozzle assembly 2530.

The nozzle assembly 2530 may include a nozzle 2534 configured to extrudematerial (received from the material feeding system 2550) through anoutlet 2532, and a trowel 2536 configured to shape material extruded bythe nozzle 2534. Because of the imprecision involved in positioning, anadaptive fine positioning platform equipped with a global sensingmechanism (e.g., a laser tracker) may be used for nozzle positioning.

If the robotic arm 2520 could be made of a rigid structure, positionsensing at the end effector may not be necessary. Instead, a positionsensor 2560 may be mounted on the robotic base 2510. The position sensor2560 may be a laser tracker, for example. In this configuration, themobile robot 2500 does not engage in construction while in motion. Onceit reaches a desired predetermined post, it may anchor itself byextending solid rods (not shown) from the bottom of the mobile robot200. Then the mobile robot 2500 may start the fabrication process,picking up from the last point of fabrication, while at the previouspost.

FIG. 26 illustrates the mobile robotic system shown in FIG. 25 beingused to construct a wall. In its upright position the mobile robot 2500can reach the top of relatively high walls. The mobile robot 2500 mayposition itself at each of the four corners of a room, and each timebuild the layer section of the wall within its reach. The mobile robot2500 may return to energy charging and material fill location, whenneeded.

Instead of using a single mobile robot that controls a single nozzleassembly, a plurality of nozzle assemblies may simultaneously beemployed. Each may be attached and controlled by the arm of a smallmobile robot dedicated to that nozzle assembly. The mobile roboticsapproach may have features such as ease of transportation and setup,scalability in terms of the number of robots deployed per project, andpossibility of concurrent construction where multiple mobile robots workon various sections of the structure to be constructed.

FIG. 27 illustrates a plurality of the mobile robotic systems 2500,shown in FIG. 25, operated concurrently for construction. The positionand actions of this workforce of mobile robots 2500 may be directedwirelessly by a central command station. As seen from FIG. 27, each oneof these small robots, in turn, may include on-board material containersor tanks that contain the necessary materials that are extruded. Thesesmall mobile robots 2500 may return to a central filling station torefill their tanks when needed. In building a multi-story structure anelevator may be used to transport the mobile robots 2500 to variousfloors. The mobile robots 2500 may be assigned to perform differentjobs, e.g. construction, plumbing, or tiling.

In another embodiment of a robotic system, a mobile robotic system maybe equipped with a motorized wheel assembly. FIG. 28 illustrates anembodiment of a mobile robotic system 2800 that is equipped with amotorized wheel assembly 2810. The mobile robotic system 2800 includes anozzle assembly 2830 coupled to the motorized wheel assembly 2810, and amaterial feed system 2820 (including a container and a delivery arm)mounted on the motorized wheel assembly 2810 and configured to feedmaterial to the nozzle assembly 2830. The material feed system 2820 mayinclude a container 2822 and a feeding tube 2826.

The robotic system 2800 fills the container of the material feed system2820 by stopping at one or more filling stations pre-installed at theconstruction site, adjacent to a wall to be constructed. The roboticsystem 2800 may be powered by a electric line, battery, or an on-boardgas generator. The configuration illustrated in FIG. 28 may bewell-suited for long walls, such as fences or factory and warehousewalls.

FIG. 28 illustrates the robotic system 2800 constructing a straightwall. The direction of the motion is toward the left, as indicated bythe arrow shown in FIG. 28. Multiple materials may be used in thisimplementation, e.g. different materials may be used for outsidesurfaces and for core structures, respectively.

FIG. 29 illustrates the mobile robotic system shown in FIG. 28 beingused to create corners. The nozzle assembly 2826 may rotate, underon-board computer control, with respect to the vertical axis of thefeeding tube 2826. Also, the material container 2822 and the feedingtube 2826 to which it is attached can rotate 360 degrees. This allowsfor creation of various structure shapes, such as corners. Concurrentcontrol of the wheel assembly, rotation of the material container andtransfer tube, and the CC nozzle orientation may be used to createvarious geometrical features.

FIG. 30 illustrates the mobile robotic system 2800 shown in FIG. 29climbing from a completed layer to the next layer. As seen in FIG. 30,the wheel assembly 2810 may swivel, so that the robotic system 2800 mayclimb each completed layer. The climbing action, combined with a 180degree rotation of the material container 2822 and the nozzle assembly2830, may also accomplish the construction of wall ends. The roboticsystem 2800 may build as much of a wall layer as possible, and when itreaches very close to the end of the layer, it may rotate the nozzleassembly 180 degrees, then move backward to climb the layer just built.Before climbing, the robotic system 2800 may waiting enough for materialto cure.

Rigid horizontal members may be used to facilitate the construction ofwindows, door openings and ceilings by bridging openings beneath them.To create a window, for example, the controller of a nozzle assembly mayturn off the flow of material to all outlets in the nozzle assembly whenthe nozzle assembly is traversing an area that has been designated asthe window opening. After the top of the walls surrounding the windowhave been extruded, a rigid horizontal member may be placed across thetop of these walls to create the header of the window. One or morecontinuous layers of material may then be extruded on top of the headerand the surrounding walls. A similar bridging approach may be used tocreate door openings. A ceiling may similarly be created by placing aseries of neighboring structural members across the top walls of astructure, over which material may be extruded to give strength to thestructure.

One or more of the robotic systems described above may also be used toplace these structural members where needed, i.e., across the tops ofwindow and door openings and across the tops of wall structures toprovide a roof.

A variety of techniques may also be employed in an automated fashion toreinforce the strength of walls that are extruded. These techniques mayinclude the automated insertion or embedding of clips across or withinthe rims of the walls periodically along their length. Thesereinforcement mechanisms may also include the insertion of rigidvertical members within the interior of the wall, including, in certainembodiments, rigid horizontal links between these vertical members.Again, all of this may be accomplished under automated robotic control.

FIG. 31 illustrates the insertion of reinforcement staples 3110 by arobotic arm 3120 coupled to a nozzle assembly 3130. The controllablerobotic arm 3120 may have at its distal end a gripper 3140 configured topick up a desired element, and deposit the element at a desired positionrelative to the extruded material.

As shown in FIG. 31, the robotic arm 3120 may insert the reinforcementstaples 3110 onto rim material that has just been extruded, in order tofurther secure the positional accuracy and strength of the rim material.The material for the staples 3110 may be made out of a metal strip or acomposite strip, which unrolls from a reel and is cut and shaped intothe final form by a mechanism installed on a gantry platform (shownpreviously) which holds the nozzle assembly 3130.

FIG. 32 illustrates reinforcement of a wall by insertion of verticalrods. To use steel reinforcement for walls, simple steel rod modules3210 may be used. These modules 3210 may be a few wall layers high, andmay be robotically inserted in the wall core material during layerconstruction. The placement of the rods 3210 may be such that eachseries overlaps with the previous series, in order to ensure continuityin reinforcement along the wall height.

FIGS. 33A, 33B, and 33C illustrate the insertion of reinforcementelements for walls. As shown in FIG. 33A, more complex and strongersteel reinforcement may be built by creating two or three dimensionalsteel mesh within walls and columns using a progressive and layer wiseapproach. In the illustrated embodiments of reinforcement structures,three steel elements 3310, 3312, and 3314, as well as two roboticmanipulator arms 3320 and 3330 (each having grippers 3322 and 3332) maybe used.

As shown in FIG. 33B, a two dimensional mesh may be built for walls byfirst imbedding rigid vertical members at equal distances, and buildinga wall rim on their sides using a nozzle assembly as previouslydescribed. Several layers may be built by the nozzle assembly to coverone layer of the mesh. A first set of rigid vertical members 3306 thatincludes an external threaded portion may first be inserted on anextruded layer, leaving the threaded end of the first vertical memberuncovered. For each successive mesh layer, a second set of rigidvertical members 3308 may be screwed by a robotic arm 3320 on top of thevertical members 3306 previously embedded at the lower mesh layer.

As shown in FIG. 33C, after assembling each two rigid vertical members3312, a rigid horizontal link 3310 may be inserted in the correspondingholes 3314 on the base of the vertical elements. The wall fabrication bya nozzle assembly may then continue, and the process may be repeated forthe next mesh layer, once an adequate height has been reached.

FIGS. 34A, 34B, 34C, 34D illustrate the insertion of reinforcementelements for columns. As shown in FIG. 34A, for columns verticalreinforcement elements 3410 may be placed at equal distances on thelattice points of a two dimensional matrix. Each member 3410 may bescrewed onto a corresponding element 3412 at a lower mesh layer.

FIG. 34B illustrates rigid horizontal links 3420 which are then insertedbetween the vertical elements 3410 to create a horizontal 2Dreinforcement mesh for each mesh layer.

As shown in FIG. 34C, the rims 3445 of the column are then constructedusing a single-orifice nozzle assembly, as shown in the FIG. 1 in thisdisclosure.

As illustrated in FIG. 34D, the hollow space between the rims 3445 maybe filled with filler material, e.g. concrete, and the process maycontinue for the subsequent layers.

Other types of reinforcement structures and methods may be used. Forexample, simpler reinforcement modules and/or robotic welding may beused, instead of screwing methods. Welding may not require as muchalignment precision as needed for attaching the reinforcement elementsby screw action.

Plumbing may also be installed as part of the automated process.Segments of plumbing pipe may be secured to other segments usingautomated installation and welding techniques.

FIG. 35 illustrates the installation of vertical plumbing pipe segments,under automated robotic control. The robotic systems and associatednozzle assemblies, described above, can build utility conduits withinthe walls, as shown in FIG. 35. Plumbing automation is thus madepossible.

FIG. 35 illustrates a segment 3510 of a metal (e.g. copper or othermaterial) pipe being attached onto a lower pipe segment 3512, afterseveral wall layers have been fabricated. A robotic arm 3520 is shown asdelivering the pipe segment 3510 on top of the previously inserted pipesegment 3512. The robotic arm 3520 has a gripper 3522 at a distal end.The gripper 3522 is configured to pick up an element and deposit theelement at a desired location relative to the extruded layers. Therobotic arm 3520 also has a heater element 3530 at the distal end. Theheater element 3530 is shown in FIG. 35 as being shaped as a ring,although heater elements having configurations other than annularconfigurations may also be used.

In the illustrated embodiment, the inside or outside rim of each pipesegment may be pretreated with a layer of solder. The ring-shaped heaterelement 3530 may heat the connection area, and melt the solder. Once thealignment is made, the heater element 3530 may bond the two pipesegments together. The heater element may use, for example, a nichromewire coil which is electrically activated. Alternatively, it may use agas burner, or other types of heating mechanisms. The robotic armconfiguration illustrated in FIG. 3 may be suitable for pipe segmentshaving a substantially vertical and straight configurations. The roboticarm 3520 may have a hollow tubular shape, and include an inner barrel.The pipe segments may be fed through the barrel of the robotic arm froma feeding magazine.

FIG. 36 illustrates a robotic arm 3610 including a plurality of grippers3620 (some of which are not fully shown) configured to grasp desiredelements from different orientations. The embodiment of the robotic armillustrated in FIG. 36 shows a universal passive robotic gripper havinga three-grippers-in-one configuration, although of course othervariations are possible. The robotic arm 3610 also has a heater element3640. The grippers 3620 at the end of the robotic arm 3610 are capableof picking, holding, and delivering the above plumbing components in theorientations shown in FIG. 36. By simply being lowered onto each of theplumbing components in their magazine rack, each gripper 3620 of therobotic arm 3610 may grab the component. The heater element 3640 maysplit open, then close to engage the area to be heated.

FIG. 37 illustrates another embodiment of a robotic gripper 3710 havinga movable heater element 3720 configured to grasp plumbing pipe segments3730 that have a downward opening. The illustrated robotic gripper 3710is configured to deliver and attach the pipe segments 3730 in the shownorientation. The heater element 3720 is made of two separate sections,i.e. includes a first component and a second component movable from anopen position in which the components are space apart to a closedposition in which the components are in engagement so as to capture atleast a portion of a desired pipe segment. As the gripper 3710approaches a pipe segment (which is in a magazine) from above, thesurface of the pipe segment first pushes the two halves of the heaterelement 3720 apart to split them open. The pipe segment then passesthrough, and gets engaged in, the gripper 3710. At this point the heaterelement halves close and are in engagement to become properly positionedaround the desired section of the plumbing segment.

In the previously described plumbing methods, plastic tubing may be usedinstead of copper tubing. When plastic tubes are used, glue may beapplied to the joints prior to connection. Automatic glue dispensingsystems may be used in assembly operations.

FIG. 38 illustrates the installation of horizontal plumbing pipesegments 3815, for example on floors. For horizontal plumbing on thefloor, a plurality of pins 3810 may be used. Each of the pins 3810 mayhave a sharp end 3812, and have a gripper 3814 at the other end, asshown in FIG. 38. The sharp end 3812 of the pins 3810 may be roboticallyinserted into the ground, at desired locations. Pipe segments 3815 maythen be inserted on the gripper end 3814 of the pins 3810, for securepositioning. Connections and assemblies may then be performed, asexplained previously. A network of pipes may be created at variouselevations by using pins of various heights. Once completed, the floormay be covered by construction material, such as concrete, using anozzle assembly described previously.

The exposed sections of pipes having an upward opening may normally bepositioned under the walls which would later be constructed using theextrusion nozzles described earlier. Over each exposed pipe section aconduit may be constructed, and a pipe section may be periodically addedto the plumbing network, after a predetermined number of wall layershave been built up.

FIG. 39 illustrates alignment of pipe segments, when assembling aplumbing pipe network. To align pipe segments when assembling a plumbingpipe network, a number of methods may be used, for example injection offoam, and attachment of dissolvable cones.

After placing each pipe segment 3910 within a conduit 3920, a foam 3915that cures quickly may be injected in the conduit, when using the foaminjection method for aligning pipe segments. Once cured, the foam 3915keeps the pipe segments 3910 in position, and facilitates alignment whenadding successive pipe segments.

As another method, by pre-attaching a dissolvable porous cone 3940 toeach pipe segment, the alignment task may be greatly simplified. Oncethe plumbing is completed, running water through the pipes woulddissolve and eliminate the cones 3940. The cones may be made of harmlessmaterials such as sugar.

FIG. 40 illustrates the shielding of plumbing networks. As seen in FIG.40, for maintainability and other purposes the horizontal sections ofplumbing networks may be covered by shields 4010. The shields 4010 maybe robotically placed by a robotic arm 4005 over the horizontally laidplumbing pipes prior to pouring the wall filler material.

Electrical wiring may similarly be installed as part of the automatedprocess. Electrical wires may be housed in modules that are connectedtogether within the walls, again under robotic control.

FIG. 41 illustrates electric modules 4110 used in one embodiment of amethod and system for automated installation of electrical andcommunication networks, in the course of constructing a structure usingextrusion methods described above. This modular approach may be similarto the approach used in building plumbing networks as described above.The electric modules 4110 shown in FIG. 41 contain segments of wires orother conductive elements, for power and communication lines. Theseconductive segments are encapsulated in nonconductive blocks, which maybe made of nonconductive materials including but not limited to plastic.The ends 4120 of the conductive segments are either conical holes orpins, or have other forms conventionally used in electrical andelectronics outlets, jacks, etc. Modules 4110 of many different types ofelectrical components may be made and used, allowing for the creation ofany desired electric network.

FIG. 42 illustrates a robotic gripper that grasps and inter-connect theelectric modules shown in FIG. 41. As shown in FIG. 42, the electricmodules 4110 are robotically fed and connected by a robotic gripper4210, which can perform the task of grabbing a desired electric module4110, and connecting the grasped module to another matching electricmodule 4112.

FIG. 43 illustrates the positioning of the electric modules withinconduits built in the walls. As shown in FIG. 43, some of the electricmodules 4110 allow for connection of electrical and communicationoutlets. By automated robotics, these modules 4110 may be positionedbehind corresponding conduits 4310 on the walls. The only manual part ofthe electrical work may be the simple task of inserting fixtures 4320into the automatically constructed electric network, part of which isshown in FIG. 43 using reference numeral 4300.

Tiling and even painting may similarly be done under robotic control.

FIG. 44 illustrates automated tiling of floors. As shown in FIG. 44,tiling of floors and walls may be automated by using a first robotic arm4410 to deliver and spread mortar or adhesive material on the floor,then using another robotic arm 4420 to pick up the tiles 4430 fromstacks 4432 of tiles, and accurately place them over the area treatedwith the adhesive material. The robotic arm 4420 used to pick up thetiles 4430 may have a suction cup gripper 4422 operable to pick up andrelease the tiles by vacuum suction, as shown in FIG. 44. Otherembodiments of the robotic arm 4420 may instead use a simple gripperthat grabs the tiles on the edges, for the tile pick-and-placeoperations.

FIG. 45 illustrates automated tiling of walls. The process for tiling ofwalls is similar to the process for tiling of floors, shown in FIG. 44.Both the material feeding tube (not shown in FIG. 45) and the roboticarm 4505 that picks up the tiles 4510, may tilt to conform to both floorand wall tiling applications. In case of vertical tiling, if a distanceis desired between the tiles, a plurality of small spacers 4520 may beplaced on one side of each tile which faces upward or downward. Thespacers may help stop the drifting of tiles by force of gravity. One ofthe major time saving aspects of the proposed tiling automation may bethe elimination of the task of aligning the tiles, which takes upconsiderable time during the manual tiling process.

FIG. 46 illustrates automated painting of the surfaces of the structuresthat have been constructed. A painting system carried at one end of acontrollable robotic arm (which is coupled to a nozzle assemblydescribed previously) may be configured to controllably paint a desiredpattern on a surface of extruded material, in accordance with a desiredspecification. After completion of a given number of layers of walls,and before placing the roof, the painting system at the end of therobotic arm may paint every wall of the constructed structure accordingto desired specifications. The painting mechanism may be a simple rollerto which liquid paint is automatically fed, a spray nozzle, or an inkjetprinter head, for example inkjet printer heads used for printing largebillboards. The inkjet printer painting mechanism may allow wall paperor other desired patterns to be printed on each wall.

As an alternative approach to layer-wise painting, the painting processmay be performed after all the walls are completed, and before the roofis made. If mobile robotic systems are used instead of overhead gantryrobots, then painting may be performed even after the completion roofconstruction. In the case of spray painting, positioning accuracy ofspray nozzle may not be crucial. In the case of roller painting, a fixedpressure between the roller and the wall surface may be maintained bymeans of a simple distance or pressure sensor. In the case of inkjetprinting, the robotic end-effector carrying the inkjet paintingmechanism may include a fine global position sensing/adjusting system,e.g., a laser tracker. The robotic end-effector may also include asensor to maintain a relatively fixed distance between the inkjet printhead and wall surface. For both roller and inkjet painting, theend-effector may conform to possible variations in the wall surfaceslopes.

FIG. 47 illustrates automated roof construction, for a planar roof. Forplanar roofs as shown in FIG. 47, beams 4710 may be used. Under eachbeam 4710, a thin sheet 4720 may be attached, to hold the paste roofmaterial deposited by a nozzle assembly (not shown). The beam 4710 maybe robotically picked up and positioned on the sheet 4720 by a roboticarm 4740. The roof may then be covered by suitable material delivered bya nozzle assembly. The edges of the sheets 4720 under the beams 4710 mayextend over, to allow for construction of gutter channels by a nozzleassembly. Roof construction may or may not need support beams.Supportless structures such as domes and vaults may be built withoutbeams.

A mixer-extruder assembly may be provided in association with a nozzleassembly to allow the components of a fast-curing material to be mixednear the head of the assembly.

FIGS. 48A and 48B both show a mixer-extruder assembly 4800, viewed fromdifferent angles. Construction material (such as concrete) may bedelivered in powder form to the mixer-extruder assembly 2800, where thepowder may be mixed and extruded substantially concurrently. Themixer-extruder assembly 2800 may be disposed adjacent to a nozzle head(not shown) of a nozzle configured to extrude material.

Such simultaneous mixing and extruding may alleviate some of thedifficulties of building structures with extruded paste material. Onedifficulty is that the material should cure fast enough to sustain theweight of material added at progressive stages, but the material shouldnot cure too fast because it may solidify inside the material storageand delivery systems, such as tanks, bumps, extruders, tubes, etc.Conventional concrete pumping systems may usually deliver low viscosityconcrete mix, which is relatively easy to pump or extrude. Thefluid-state concrete may typically be poured in a mold which maintainsthe shape of the cured concrete.

When using the previously described nozzle assembly for construction,typically no mold is used, and therefore the extruded concrete shouldmaintain its shape. This requires a high viscosity concrete paste, whichcures much faster than the low viscosity mix. One possibility is to usecuring retardant chemicals to control the curing time. This, however,slows the construction process, because it would require a period oftime to elapse between the deposition of successive layers. Themixer-extruder assembly may provide a solution by delivering concrete(or other construction material) in powder form near the nozzle head,and then mixing and extruding the power material substantiallyconcurrently.

The mixer-extruder assembly 4800 includes a hollow extrusion chamber4810 and a hopper 4820 connected to the extrusion chamber 4810 through achannel 4819. The chamber 4810 includes a outlet port 4812 at its lowerend, and a fluid inlet port 4816 along a side wall of the chamber. Thehopper 4820 has an input port 4822 configured to receive input materialtherethrough, and an output port 4824 configured to eject exhaustmaterial therethrough. In the illustrated embodiment, the chamber 4810has a substantially cylindrical configuration symmetrical about acylinder axis 4815. A nozzle head (not shown) may be connected to theoutlet port 4812 of the extrusion chamber 4810. The powder material maybe delivered to the hopper 4820 using conventional conveyors or air astransporter. For example, a closed circuit of flexible tubing may beused in which air circulates delivers powder material from a remote tankat the construction site to a hopper 4820 connected to the extrusionchamber 4810. Upon arrival at the hopper 4820, a great portion of thepowder settles in the hopper under gravity. When the hopper 4820 isfull, the arriving material may simply return to the source tank bymeans of the return tubing.

FIG. 49 illustrates a cross-sectional view of the mixer-extruderassembly 4800 shown in FIG. 48, and a piston drive shaft for use inoperating the mixer-extruder assembly. As shown in FIG. 49, a pistondrive shaft 4920 is provided that has a piston 4915 attached at one end,and can make reciprocal movement along a drive shaft axis 4922, as wellas being rotatable about the drive shaft axis 4922. One or more mixerblades are coupled to the piston 4930. In the embodiment of themixer-extruder assembly illustrated in FIG. 48, two mixing blades 4930are secured on each end by rigid close rings, and are positioned withinrespective slots 4932 in the piston 4930 in such a way that they canslide in and out of the slots 4932. The blades 4930 may be positioned atan angle that allows them, upon rotation along the drive shaft axis4922, to mix and agitate the powder material to which water (or othermixing liquids) have been added through the fluid inlet port 4816 bymeans of a metering valve (not shown).

FIG. 50 illustrates the operation of the mixer-extruder assembly 4800shown in FIGS. 48 and 49, as the piston 4915 is moved from an upper endof the extrusion chamber 4810 toward the outlet port 4812 of the chamber4810. The operation of the mixer-extruder assembly 4800 threeoperational modes or stages. In the first, leftmost stage in FIG. 50,the piston 4915 is shown at its highest position, which is past theopening of the channel 4819 connecting the extrusion chamber 4810 to thepowder hopper 4820. In this position, the hopper 4820 may be emptiedinto the extrusion chamber 4810 by a fixed and known amount, which maybe the volume of the cylindrical chamber 4810. A simple low resistancebarrier, such as a slotted robber sheet at the outlet port 4812 of theextrusion chamber 4810, may prevent the material from exiting thechamber.

In the second stage, shown in the middle of FIG. 50, the piston islowered just past the opening of the hopper channel 4819, therebyclosing the chamber 4810. At this point the metered mixing liquid isinjected into the chamber 4810 through the fluid inlet port 4816, whilethe piston 4915 rotates, and the blades 4930 perform the mixing andagitation. Agitation typically prevents concrete from setting.

In the third and rightmost stage shown in FIG. 50, the piston 4915 islowered further, while in rotation, to extrude the paste through theextrusion chamber outlet port 4812, and into the nozzle head (notshown). When the chamber 4810 is emptied, the piston is raised to theinitial position (leftmost stage), and the cycle continues anew. Thepowder hopper 4820 may fill quickly, while extrusion takes place. Twosuch mechanisms working in parallel, and feeding into the same nozzle,may provide a continuous flow of construction material in paste form. Atthe end of the operation, the empties cylinder may be cleaned byflushing it with water coming in through the fluid inlet port 4816,while the piston rotates and reciprocates between the second and thethird stages.

The extrusion mechanism described in conjunction with FIG. 50 may havenumerous applications outside the construction domain, including but notlimited to the food processing industry, dental impression, and materialmixing and delivery.

As an alternative to the above-described mixer/pump mechanism, single ortwin screw pumps with mixing capability may be used with the nozzleassembly described previously.

By combining some or all of the features described above into a singlesystem, the vast majority of a sound and quality structure may be builtaccording to custom specifications very quickly, efficiently, accuratelyand with few personnel.

Although now having described certain embodiments of nozzle assemblies,robotic systems, and automated construction, it is to be understood thatthe concepts implicit in these embodiments may be used in otherembodiments as well. In short, the protection of this application islimited solely to the claims that now follow.

In these claims, reference to an element in the singular is not intendedto mean “one and only one” unless specifically so stated, but rather“one or more.” All structural and functional equivalents to the elementsof the various embodiments described throughout this disclosure that areknown or later come to be known to those of ordinary skill in the artare expressly incorporated herein by reference, and are intended to beencompassed by the claims. Moreover, nothing disclosed herein isintended to be dedicated to the public regardless of whether suchdisclosure is explicitly recited in the claims. No claim element is tobe construed under the provisions of 35 U.S.C. §112, sixth paragraph,unless the element is expressly recited using the phrase “means for” or,in the case of a method claim, the element is recited using the phrase“step for.”

The invention claimed is:
 1. A nozzle for extruding a wall in cascadinglayers comprising: a first outlet configured to extrude a first lengthof unhardened material; a second outlet configured to extrude a secondlength of unhardened material that is spaced apart from andsubstantially parallel to the first length of unhardened material; athird outlet configured to extrude a third length of unhardened materialbetween the first and the second lengths of unhardened material; and anozzle support frame configured to adjust the separation distancebetween the first and the second outlets, thereby facilitatingadjustment of the width of the wall that is extruded by the nozzle. 2.The nozzle of claim 1 wherein the separation distance is configured tobe adjusted manually.
 3. The nozzle of claim 1 wherein the separationdistance is configured to be adjusted automatically.
 4. The nozzle ofclaim 3 wherein the separation distance is configured to be adjustedautomatically under servo control.
 5. The nozzle of claim 1 wherein thethird nozzle is configured to extrude the third length of unhardenedmaterial with a width that is substantially less than the width of thespace between the first and the second lengths of unhardened materialwhen the nozzle support frame is adjusted to cause a wide separationdistance between the first and the second outlets.
 6. The nozzle ofclaim 1 wherein third nozzle is configured to extrude the third lengthof unhardened material with a width that is substantially the same asthe width of the space between the first and the second lengths ofunhardened material when the nozzle support frame is adjusted to cause anarrow separation distance between the first and the second outlets. 7.The nozzle of claim 1 wherein the first, second, and third outlets havea rectangular cross-section.
 8. The nozzle of claim 1 wherein the firstlength of unhardened material has a width that is different from thewidth of the second length of unhardened material.
 9. A process forextruding a wall in cascading layers comprising: extruding the wallusing a nozzle of the type recited in claim 1; and varying theseparation distance between the first and the second outlets during theextrusion, thereby causing a progressive change in the thickness of thewall during the extrusion.